Container bottom and methods

ABSTRACT

Substantially triangular shaped container bottoms include a bottom wall with a concave surface. The container bottom can be used with a container body having an interior chamber for receiving at least one article. Exemplary embodiments include a container bottom attached to a container body wherein the container bottom includes a central surface area that is inwardly concave towards an interior chamber of the container body. Methods of loading a plurality of articles in a container are also provided.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.10/011,112, continuation-in-part of U.S. application Ser. No.09/851,040, filed May 8, 2001 (now abandoned), which claims the benefitof U.S. Provisional Application No. 60/202,394, filed May 8, 2000 (nowabandoned). The application also claims the benefit of U.S. ProvisionalApplication Nos. 60/248,103 (now abandoned) and 60/248,340 (nowabandoned), each filed Nov. 13, 2000. Each application is entirelyincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to container bottoms suitable for use incombination with container bodies. Containers comprising a containerbottom and body are adapted, for example, for packaging one or morepieces (i.e., one or more articles), such as frangible snack pieces. Thepresent invention further relates to methods of loading a plurality ofarticles in a container.

BACKGROUND OF THE INVENTION

Preshaped snack pieces are typically frangible and might be fragile andeasily broken during packaging, shipping and/or other handlingoperations. Conventional packaging techniques provide bags and/or boxesthat can permit a significant number of the snack pieces to break orcrush prior to consumption. The well known Pringles® shaped potato chipsnack pieces, a product of The Procter & Gamble Company, Cincinnati,Ohio, are individual snack pieces having a “saddle” shape and arepackaged in a manner which overcomes disadvantages of the prior art. ThePringles® snack pieces have conventionally been packaged as a singlenested stack in a cylindrical container which provides enhancedprotection during packaging, shipping and/or other handling. As aresult, the Pringles® snack pieces are typically presented to theconsumer without breakage.

The “saddle” shape of the Pringles® snack pieces provide oppositelyfacing concave surfaces that present curved edges to engage a planarportion of the container when loading the chips. Pringles® snack piecesmay be loaded by horizontally positioning an elongated circularcylindrical container and thereafter horizontally inserting a stack ofsnack pieces therein. As the snack pieces are inserted, the leadingsnack pieces typically tip over out of proper alignment with theremaining stack until the outer edge of the leading snack piece engagesa flat planar surface of the bottom wall wherein the curvature of theouter edge of the snack piece facilitates reorientation of the leadingsnack piece to form a nested stack of snack pieces.

There is a continuing need for user-friendly, relatively inexpensivecontainers for packaging various frangible snack pieces to provideprotection against breakage during packaging, shipping and/or otherhandling. It is further desired to provide containers that facilitateloading of snack pieces during production. There is further demand forcontainers that provide a user-friendly package and provide oxygen andmoisture protection to prevent spoilage of snack pieces containedtherein.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides container bottoms which canbe used in combination with container bodies and methods of loadingarticles. Each container bottom according to the present invention canbe used in combination with a container body to package one or morepieces, such as substantially triangular pieces. In one application,containers may be used to package snack pieces. For example, thecontainers may be used to package a stack of substantiallytriangular-shaped snack pieces to provide consumers with a producthaving minimum breakage prior to consumption.

In accordance with exemplary embodiments of the present invention, asubstantially triangular shaped container bottom includes a bottom wallwith a concave surface.

In accordance other exemplary embodiments of the present invention,containers are provided. The containers include a container bodydefining an interior chamber and a container bottom attached to thecontainer body. The container bottom includes a central surface areathat is inwardly concave towards the interior chamber.

In accordance with additional embodiments, combinations are provided.Each combination includes a container with a container body defining aninterior chamber and a container bottom attached to the container body.The container bottom includes a central surface area that is inwardlyconcave towards the interior chamber. A plurality of articles aredisposed in a nested stack in the interior chamber of the container. Thearticle adjacent the container bottom includes a convex surface engagingthe concave surface of the container bottom.

In still further embodiments of the present invention, methods ofloading a plurality of articles in a container are provided. The methodsinclude the steps of providing a container defining an interior chamberand a bottom wall including an inner surface. A stack of articles isprovided and is inserted at least partially into the interior chamberuntil the leading article of the stack of articles contacts the innersurface of the bottom wall with an Angle Between Tangent(s) (“ABT”) ofless than or equal to about 45°. The leading article is reoriented byforcing the leading article against the inner surface.

Advantageously, the container bottoms, containers, combinations andmethods according to the invention provide improved packaging for piecessuch as substantially triangular-shaped snack pieces. Additionaladvantages and objects will be more fully apparent in view of thefollowing detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim the present invention, it is believed that thepresent invention will be better understood from the followingdescription of specific embodiments, taken in conjunction with theaccompanying drawings, in which like reference numerals identify likeelements, and wherein:

FIG. 1 is a perspective view of one embodiment of a substantiallytriangular shaped container in accordance with the present invention;

FIG. 2 is an elevational side view of a portion of the container of FIG.1;

FIG. 3 is a schematic sectional illustration of a horizontally disposedcontainer with concave snack pieces being inserted therein wherein theleading snack piece is at least partially tipped over out of properstacked alignment;

FIG. 4 is a schematic sectional illustration of a horizontally disposedcontainer with the concave snack pieces being further inserted to apoint where the leading concave snack piece initially contacts theinwardly concave bottom surface;

FIG. 5 is a schematic sectional illustration of portions of thecontainer in a vertical position after the snack pieces have beeninserted therein;

FIG. 6 is a perspective view of a spherically concave snack piece inaccordance with one aspect of the present invention;

FIG. 7 is a bottom plan view of the substantially triangular containertaken along line 7-7 of FIG. 2;

FIG. 8 is a fragmentary partial cross-sectional view of the container ofFIG. 1 taken along a line bisecting one corner and intersecting amidpoint of the opposite side;

FIG. 9 is an enlarged partial view of the Detail 9 in FIG. 8, showingportions of the container bottom;

FIG. 10 is a partial schematic view of FIG. 9;

FIG. 11 is a schematic partial cross-sectional view taken along line11-11 in FIG. 7;

FIG. 12 is a schematic partial cross-sectional view taken along line12-12 in FIG. 7;

FIG. 13 is a bottom plan view of a substantially triangular containerbottom in accordance with another embodiment of the present invention;

FIG. 14 is a top plan view of the substantially triangular containerbottom of FIG. 13 showing the inwardly concave bottom surface;

FIG. 15 is a sectional view taken along line 15-15 of FIG. 14;

FIG. 16 is a bottom plan view of a substantially triangular containerbottom in accordance with yet another embodiment of the presentinvention;

FIG. 17 is a top plan view of the substantially triangular containerbottom of FIG. 16 showing the inwardly concave bottom surface;

FIG. 18 is a sectional view taken along line 18-18 of FIG. 17;

FIG. 19 illustrates exemplary concave surfaces in accordance with thepresent invention;

FIG. 20 is a top plan view of a substantially triangular containerbottom in accordance with another embodiment of the present inventionshowing an inwardly cylindrically concave bottom surface;

FIG. 21 is a sectional view along line 21-21 of FIG. 20;

FIG. 22 is a top plan view of a substantially triangular containerbottom in accordance with another embodiment of the present inventionshowing an inwardly cylindrically concave bottom surface;

FIG. 23 is a sectional view along line 23-23 of FIG. 22;

FIG. 24 is a partial sectional view of a substantially triangular snackpiece in accordance with the present invention;

FIG. 25 is a sectional view along line 25-25 of FIG. 24;

FIG. 26 is a partial sectional view of another substantially triangularsnack piece in accordance with another embodiment of the presentinvention; and

FIG. 27 is a sectional view along line 27-27 of FIG. 26.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Exemplary embodiments of the present invention comprise substantiallytriangular-shaped container bottoms. Further exemplary embodimentscomprise containers including container bottoms and correspondingcontainer bodies. Container bottoms described throughout thisapplication intend to include the closed end of the container whenloading a plurality of chips through the open end. Thus, the containerbottom could eventually function as either the container bottom or thecontainer top after loading and packaging the snack pieces. For example,the container bottom could comprise the membrane lid that willeventually function as a removable lid after loading the container andsealing the open end of the container with a closure that eventuallyfunctions as the bottom of the container. Alternatively, as illustratedin FIGS. 1-5, the container bottom could also function as the bottom ofthe container once the snack pieces are loaded and packaged within thecontainer.

Exemplary containers are disclosed in the copending U.S. ProvisionalApplication No. 60/248,340 of Buisson et al. filed Nov. 13, 2000,entitled “An Improved Plastic Package for Snack Pieces.”

It will be understood that each of the containers of the presentinvention may comprise a container bottom that is integrally formed withthe container body. For instance, both the container bottom and thecontainer body may be formed simultaneously during a blow moldingprocess. In alternative embodiments, each container body and containerbottom may be formed separately and thereafter attached to one another.In one example, the container bottom can be slid over or within thecontainer body and then attached by adhesive, thermal bonding, or thelike. In still further embodiments, the container bottom may be attachedto the container body after abutting one against the other. Anintermediate attachment portion, such as a substantially triangular bandof material, may also be provided to attach the container bottom to thecontainer body.

The containers used in accordance with the present invention permitpackaging of one or more pieces (i.e., one or more articles), such assubstantially triangular-shaped pieces. In one application, one or moresnack pieces may be packaged, and in particular embodiments, one or moresubstantially triangular-shaped snack pieces may be packaged to presentconsumers with an accessible product with minimal breakage. It iscontemplated that a wide variety of snack pieces may be packaged with acontainer having a wide variety of cross-sectional shapes. For example,containers having substantially circular, substantially elliptical,substantially rectangular, substantially square, substantiallytriangular (e.g., see FIG. 1), or other shapes could be provided inaccordance with the present invention to package snack pieces havingsubstantially triangular (e.g., see FIG. 6), substantially circular,substantially elliptical, substantially rectangular, substantiallysquare or other shaped snack pieces such as chips (e.g., tortilla chips,potato chips, vegetable chips, fruit chips, bagel chips), crackers,biscuits, cookies, candy, or the like. Each of the above mentionedexemplary snack piece shapes could be packaged in alternate containershaving one or more of the above-referenced container shapes. Whileexemplary embodiments of the present invention are described for usewith edible snack pieces, the containers of the present invention mayalso be useful to store, package and/or ship other piece(s), including,but not limited to, a plurality of frangible or fragile pieces (i.e., aplurality of frangible or fragile articles) in a stacked relationship.

The interior surfaces of the containers of the present invention may bestructured to assist in loading the pieces, such as the snack pieces, aswell as supporting the articles after packaging. For example, as a stackof snack pieces are horizontally inserted into an elongated container, adomino effect might occur as the leading and successive snack pieces tipover out of proper alignment. Snack pieces might tend to tip over out ofproper stacked alignment due to various factors, for example, lowerloading speeds, insufficient acceleration as the snack pieces are beingloaded, orientation of the container or stack of pieces, or the like.

Typically, a bottom wall of the container may not have a surfaceadequate to realign exemplary snack pieces and/or may result in snackpiece breakage as the leading snack piece contacts the container bottomwall. For example, the leading snack piece may resist rotation to theproper position once it contacts the bottom wall, thereby possiblyresulting in crushed snack pieces as the remaining stacked snack piecesare forced into the container. Alternatively, one or more leading snackpieces may rotate further out of proper alignment as the remaining snackpieces bypass the one or more misaligned snack pieces. Accordingly, thebypassed or slipped snack piece(s) remain disposed adjacent theremaining stack of snack pieces, thereby possibly causing aninterference problem, or presenting an inconvenience and/or disorganizedappearance to the consumer. In another example, the failure of theleading snack piece to properly align may result in misalignment of theentire stack of snack pieces. Such misalignment prevents efficient useof the container space and therefore may prevent all of the pieces fromsufficiently entering the container. Indeed, the outermost pieces of thestack may fall from the container, thereby contaminating the surroundingenvironment and/or preventing insertion of a sufficient number of snackpieces in the container.

In order to prevent or delay the snack pieces from tipping over and outof proper alignment, the snack pieces might be accelerated and/or loadedat higher velocities. However, excessive snack piece velocity duringpackaging can result in breakage due to the momentum of the snack piecesand resulting impulse from a sudden collision with the bottom wall.

In accordance with the present invention, each of the container bottomsincludes a bottom wall with a surface that is structured to permitreorientation of a leading snack piece being inserted in the container.In exemplary embodiments, the lower wall can be planar for contact witha sufficiently convex surface of a snack piece. In additional exemplaryembodiments, the bottom wall is substantially inwardly concave towardsan interior chamber to engage with a convex surface or a planar surfaceor edge of a snack piece. The inwardly concave surface of the bottomwall minimizes snack piece breakage and misalignment when loading thesnack pieces for packaging. Convex surfaces of the snack pieces maycooperate with the inwardly concave bottom wall of the container toassist in rotating the leading snack piece, and thereafter the remainingsnack pieces, into a properly aligned stacked position. The inwardlyconcave surfaces of the bottom wall also assist in reducing the impulseforce acting on snack pieces engaging the bottom wall. The snack piecescan be loaded at various loading velocities. Increased loading velocityis desired to reduce the loading time for packaging the stack of snackpieces in the container. However, the loading velocity should not be setso high as to cause snack piece breakage. Providing an inwardly concavesurface can reduce the magnitude of the impulse acting on the snackpiece as it contacts the bottom wall. Accordingly, the maximum loadingvelocity can be increased by providing the bottom wall with an inwardlyconcave surface.

As described above, the interior surfaces of the container may bestructured to permit orientation of the snack pieces to minimize theextent of snack piece breakage that might otherwise occur after thesnack pieces are loaded in the container. The structure of the interiorsurfaces may also be arranged to enhance the accessibility of theproduct to the consumer. For example, providing a container with a flatbottom may not provide an adequate distribution of force over thesurface area of a snack piece with a convex lower surface and a concaveupper surface. For instance, in a flat bottom container, the leadingsnack piece loaded in an upwardly concave manner would be required tosupport the weight of the entire snack piece stack along a contact areacomprising the central point or central location of the snack piece incontact with the flat bottom wall. Alternatively, loading the snackpieces in a downwardly concave manner would require the leading snackpiece to support the weight of the snack piece stack along a contactarea comprising the outer edges of the snack piece in contact with theflat bottom wall. Due to the frangible nature of the snack pieces, theymay break or crush due to the excessive stresses at the contactlocations.

In accordance with exemplary embodiments, the bottom wall of thecontainers include an interior surface with a substantially concaveshape towards the interior chamber to facilitate loading snack piecesand to permit upwardly concave stacking, thereby minimizing stressconcentrations in the snack piece while presenting the snack piece edgescloser to the top of the container to facilitate removal by theconsumer. Alternatively, it is contemplated that the bottom wall may beconstructed with a surface that is substantially inwardly convex towardsthe interior chamber. The convex surface may minimize stressconcentrations in the snack piece being supported by the bottom wallsuch that the convex surface conforms to a concave surface of the snackpiece. However, loading the snack pieces in this manner would requirethe snack pieces to be oriented such that they are concave towards thebottom wall, thereby positioning the snack piece edges farther away fromthe top of the container than the central portion of the snack piece.Removal of the snack pieces by grasping the edges is difficult whenpositioning the snack piece edges farther away from the top of thecontainer. Moreover, loading of the snack pieces may result in snackpiece breakage since the inwardly convex bottom wall surface of thecontainer can trap, rather than facilitate reorientation, of the snackpieces contacting the bottom wall.

Referring now to the drawing figures in detail, wherein like numeralsindicate the same elements throughout the views, FIG. 1 depicts asubstantially triangular-shaped container 30 for stacking a plurality ofsnack pieces 70 (e.g., see FIG. 6). Within the context of the presentinvention, “substantially triangular-shaped” generally includes athree-side polygonal shape wherein the sides are connected with oneanother at respective corners which comprise a sharp angle or a morerounded configuration. The comers connect straight or substantiallystraight sides. Within the present invention, “straight” may include adistance between the comers, rather than requiring any surface orcross-sectional configuration of the sides. In exemplary embodiments,the container bottom has a substantially equilateral triangular shape,wherein the sides of the triangular shape are of equal or substantiallyequal length. In other embodiments, the container bottom has asubstantially isosceles triangular shape, wherein two sides of thetriangular shape are of equal or substantially equal length.

The container 30 can be formed from a variety of materials including oneor more of the following: paper products (e.g., cardboard, corrugatedcardboard, corrugated paper, kraft paper, extensible paper); plastic;composites of plastic and/or paper; laminates of plastic and/or paper;aluminum foil; metals, or the like. In one example, the container 30 maybe formed of a thermoplastic material and can be blow molded, althoughother production methods may be employed. Suitable thermoplasticmaterials include, but are not limited to, polyolefins, such aspolyethylene and polypropylene, vinyl polymers such as ethyl vinylalcohol (EVOH), or the like. These materials might be monolayered ormultilayered, wherein different layer materials may be combined. Forexample, a multilayer material may include both a polyolefin layer andan EVOH layer. In a specific embodiment, the container 30 is blow moldedfrom a multilayer material comprising a layer of EVOH sandwiched betweentwo layers of high density polyethylene (HDPE). The container cantypically have a wall thickness from about 0.013 cm to about 0.140 cm.

The containers of FIG. 1 include a container body 34, a container bottom38 and a lip 32. In one particular embodiment, the containers are ablow-molded, multiple-layer plastic structure including: a virginpolyolefin layer, a tie layer, a layer of EVOH, another tie layer, andanother virgin polyolefin layer. Typically, container 30 will also haveone or more layers of regrind material between at least one of the tielayers and the virgin polyolefin layers. The layer of EVOH might be noless than 0.00005 inches thick and no thicker than 0.006 inches, forexample no less than 0.00005 inches and no greater than 0.003 inches andin another more specific example, no less than 0.0001 inches and nogreater than 0.0012 inches.

An even more particular example of this multilayer plastic structurecomprises a six-layer structure including the following layers (from theoutside layer to the inside layer): about 9.31 grams (g) or about 19.4%by weight of HDPE; about 18.91 g or about 39.4% by weight of plantregrind and HDPE; about 0.62 g or about 1.3% by weight of a tie layer;about 2.02 g or about 4.2% by weight of EVOH; about 0.62 g or about 1.3%of a tie layer; and about 16.51 g or about 34.4% of plant regrind andHDPE. Another example of this six-layer structure can comprise (from theoutside layer to the inside layer): about 10.7 grams (g) or about 19.4%by weight of HDPE; about 21.66 g or about 39.4% by weight of plantregrind and HDPE; about 0.69 g or about 1.3% by weight of a tie layer;about 2.33 g or about 4.2% by weight of EVOH; about 0.69 g or about 1.3%of a tie layer; and about 18.94 g or about 34.4% of plant regrind andHDPE. Yet another example of this six-layer structure can comprise (fromthe outside layer to the inside layer): about 15.0% by weight of HDPEhomopolymer and color; about 63.6% by weight of plant regrind (60% byweight) and HDPE homopolymer and color (40% by weight); about 1.4% byweight of a tie layer; about 3.6% by weight of EVOH; about 1.4% of a tielayer; and about 15.0% of plant regrind and HDPE homopolymer and color.

FIGS. 1 and 2 illustrate the container 30 including a container body 34and a container bottom 38, wherein FIGS. 7-12 further illustrateexemplary features of the container bottom 38. The container bottom 38is enlarged for supporting the container 30 in an upright position andcan be dimensioned to facilitate the manufacturing process. Indeed, withreference to FIG. 5, the container body 34 has a first maximumcross-sectional width taken along an imaginary plane that isperpendicular to a geometric central axis 64 extending from thecontainer bottom 38, and the container bottom 38 has a second maximumcross-sectional width taken along another imaginary plane that isperpendicular to the geometric central axis 64. The second maximumcross-sectional width is larger than the first maximum cross-sectionalwidth. As illustrated in FIG. 5, for example, at least a portion 51 ofthe lateral cavity 50 extends a greater distance along a first radialline “d₁” extending perpendicular from the geometric central axis 64than a maximum distance between the container body and the geometriccentral axis 64 along a second radial line “d₂” parallel to the firstradial line “d₁”.

Throughout this application, the geometric central axis is the axis thatextends perpendicular to a planar projected foot print surface of thecontainer bottom and through a center of gravity of the foot printsurface. The geometric center of the container bottom is one or morepoints of the container bottom in contact with the geometric centralaxis. For example, as illustrated in FIG. 1, the container bottom 38defines a horizontal planar projected foot print surface 40 that ishorizontally oriented with a center of gravity 41. As illustrated inFIG. 3, a geometric central axis 64 extends perpendicular to the planarprojected foot print surface 40 and through the center of gravity 41 ofthe surface 40. As shown in FIGS. 7 and 8, the geometric center 54 islocated at one or more points of the container bottom 38 in contact withthe geometric central axis 64.

As illustrated in FIG. 9, the enlarged container bottom 38 includes aninner wall 56 and an outer wall 58. The inner wall 56 includes atransition portion 60 to connect the inner wall 56 with a bottom wall 42at an edge 46 of the bottom wall 42. The transitional portion 60 canfacilitate production of the container bottom 38 with a blow moldingprocess and can have a length that is sufficiently long to permit blowmolding while being sufficiently short to permit loading of snack piecesin the container without trapping the pieces in a lateral cavity 50defined between inner and outer walls 56, 58 of the container bottom 38.

The blow ratio of the lateral cavity 50 should be sufficient tofacilitate formation of the container bottom 38 by a blow moldingprocess. The blow ratio of the lateral cavity 50 can be defined as theratio of “H₁” to “W₁” (See FIG. 10), wherein “H₁” represents thevertical distance between the upper-most portion of the inner wall 56(e.g., at an upper-most part of the transition portion 60 of the innerwall 56) and the lower-most portion of the container bottom 38 andwherein “W₁” represents the distance between the outer wall 58 and theupper-most point of the transition portion 60 of inner wall 56. Inexemplary embodiments, the blow ratio may be from about 0 (e.g., a flatbottom) to about 3.0. In one exemplary embodiment, the blow ratio isabout 0.72 when “H₁” is about 0.59 cm and “W₁” is about 0.82. In anotherembodiment, the blow ratio is about 0.43 when “H₁” is about 0.59 cm and“W₁” is about 1.37 cm. One skilled in the art can readily select anappropriate blow ratio for the lateral cavity of the container bottomsof the present invention using standard blow molding techniques.

FIG. 10 also shows a lead angle “a” defined as the angle between theinner wall 56 and the vertical. The lead angle “a” may be large enoughto allow the container to be stripped or ejected from a mold withoutdamaging the container bottom 38. In one embodiment, the lead angle “a”is less than 90°. In another exemplary embodiment, the lead angle “a” isfrom about 20° to about 75°. In still another exemplary embodiment, thelead angle “a”0 is from about 30° to about 60°. Using standard blowmolding techniques, one skilled in the art can easily determinesufficient lead angles “a” to avoid complications during the blowmolding process.

Exemplary bottom walls 42 of the present invention can also comprise acentral surface area 47, as seen in FIG. 3, including an inwardlyconcave surface 44. In exemplary embodiments, the central surface area47 is defined radially about the geometric central axis 64. As shown inFIG. 3, each point of the perimeter of the central surface area 47 canextend a radial distance along a radial line “d₃” that has a length lessthan about 100% (for example, less than about 85%; and in anotherexample less than about 50%) of the maximum radial distance between thecontainer body 34 and the geometric central axis 64 along the secondradial line “d₂” parallel to the radial line “d₃”. Providing the centralsurface area with portions of the concave surface enhances effectivenessof the surface area to reorient the articles to be loaded.

As described above, the inwardly concave surface may assist in loading,packaging, and/or supporting the snack pieces. The inwardly concavesurface 44 may have a variety of shapes depending on the particularapplication. For example, the inwardly concave surface 44 may beprovided with a curvature similar or substantially identical to acurvature of the snack piece being supported. In one example, theinwardly concave surface comprises a spherical inwardly concave surface.As shown in FIGS. 8 and 9, a spherically inwardly concave surface 44 canhave a radius of curvature “R₁” with a center of curvature 62 located onthe geometric central axis 64 of the container bottom 38. As illustratedin FIGS. 7-9, the geometric central axis 64 is a tri-symmetrical axis ofsymmetry wherein the tri-symmetrical axis divides the container bottom38 in three substantially identical sections radially disposed about thegeometric central axis 64. In alternative embodiments, the center ofcurvature can be located on a bi-symmetrical axis or plane of anisosceles triangle, circle, or other bi-symmetrical shape. The center ofcurvature could also be disposed along a quad-symmetrical axis or otheraxes with increased degrees of symmetry. In further embodiments, thecenter of curvature is located outside an axis or plane of symmetry ofthe bottom wall. However, it can be beneficial to locate the center ofcurvature along an axis or plane of symmetry to assist in aligning thesnack pieces in a substantially centered orientation within the interiorchamber of the container body.

The inwardly concave surface of each of the embodiments of the presentinvention may include a wide variety of alternative configurationsdepending on the particular application. For example, as illustrated inFIG. 19, the inwardly concave surface 544 can include a surfacegenerated by rotating a function “y=f(x)+C” about the Y-axis. Forinstance, a curve, line, or series of segments can be rotated about avertical axis to generate a concave surface. FIG. 19 depicts oneparticular embodiment where a paraboloid surface can be defined byrotating a function defining a parabola “y=f(x)+C” about the Y-axis. Infurther embodiments, a spherically concave surface could be formed byrotating an appropriate function to define a sphere or hemisphere.

FIG. 19 further illustrates generating a scoop-type inwardly concavesurface 644 by rotating a function “y=f(x)+C” about the line ofcurvature (e.g., the X-axis) wherein “C” may remain the same or changeas the function rotates. The function “y=f(x)+C” could be a curve, line,series of segments or the like. In addition, the constant “C” of thefunction represents an offset distance wherein an initial offsetdistance y₁, can be different from the final offset distance y₃. In oneexample, as shown in FIG. 19, the offset distance remains constant asthe function is rotated such that y₁, Y₂ and y₃ are constant. In anotherexample, the offset distance can change during rotation wherein y₁, y₂and/or y₃ are the same or different.

In one example, the scoop-type inwardly concave surface 644 couldcomprise a portion of a circular cylindrical surface of a cylinder. Toform the circular cylindrical surface, the function “y=f(x)+C”is simplythe offset distance (i.e., y=C), wherein the offset distance remainsconstant during rotation of the function.

In another example, as illustrated in FIG. 19, the function “y=f(x)+C”could be a sinusoidal function to generate a concave waved shape surface644. Such a concave waved surface may be useful to load waved snackpieces (e.g., waved potato chips or the like). As shown in FIG. 19, thefunction can be offset from the X-axis (e.g., an initial distance y₁,intermediate distance y₂, and final distance y₃). The offset distancecould remain the same during rotation of the function about the X-axissuch that y₁, y₂, and y₃ are the same. Alternatively, the offsetdistance could change during rotation of the function about the X-axissuch that y₁, y₂, and/or y₃ are the same or different. In one example, asubstantially U-shaped concave surface could be created by initiallyincreasing the offset distance and then later decreasing the offsetdistance as the function rotates. In one particular example a U-shapedconcave surface could be created wherein y₁ and y₃ are the same while y₂is greater than y₁, and y₃. Such a surface may reduce breakage incidentsby assisting in gradual reorientation of the snack pieces duringinsertion of the snack piece stack in the container.

Thus, the inwardly concave surface in accordance with each of theembodiments of the present invention may include a wide variety ofsurface shapes including scoop-type concave surfaces (e.g., V-shaped,W-shaped, sinusoidal, corrugated-shaped or the like), circular shapes,paraboloid shapes, or the like.

In one exemplary embodiment, as illustrated in FIG. 5, the snack pieces70 can have a spherically convex surface 74 that conforms to theinwardly spherically concave surface 44 of the bottom wall 42. Asfurther illustrated in FIGS. 5 and 6, the snack pieces 70 may furtherinclude a spherically concave surface 72 adapted to conform to thespherically convex surface 74 of an adjacent snack piece. For example,exemplary triangular snack pieces 70 including a convex surface 74 witha radius of curvature similar or substantially identical to the radiusof curvature R₄ of the concave surface 72 permits the snack pieces 70 tobe loaded in a container such that they are positioned in a nestedstacked relationship relative to one another. In one particular example,as illustrated in FIG. 5, a plurality of snack pieces are loaded in anested, stacked relationship with at least one snack piece surface beingsubstantially offset from one another so that adjacent snack pieces abutone another (the offset distances between the snack pieces areexaggerated in FIG. 5 for clarity).

The container body 34 may also be shaped with an inner surface similarto the outer perimeter of the snack pieces (e.g., with a substantialtriangular shape) to assist in maintaining the stacked pieces in properalignment once the snack pieces are loaded in the container 30.Providing the exterior of the container body with a similar shape (e.g.,with a substantial triangular shape) as the inner surface of thecontainer can also reduce material costs while providing consumers withinformation regarding the snack piece shape packaged therein.

The concave surface 44 has a sufficient size to guide the snack pieces70 as they are loaded in the container 30 while the inner and outerwalls 56, 58 defining the lateral cavity 50 have a sufficient blow ratioto permit manufacture of the single piece container bottom 38 by blowmolding, as discussed above. In one embodiment, the concave surface 44has a width “W₂” between adjacent corner areas of about 50% to about 90%of the width “W₃” between adjacent corner areas of the container bottom38 (best illustrated in FIG. 7). In one example, “W₂” is about 5.06 cmand “W₃” is about 7.85 cm such that “W₂” is about 64% of W₃”.

As shown in FIG. 1, the container 30 defines an interior chamber 36 andis designed to hermetically seal snack pieces within the interiorchamber with a membrane lid 66. For example, the container 30 mayoptionally include a container membrane lid and container lip asdisclosed in U.S. Provisional Application No. 60/248,026, filed Nov. 13,2000, and also U.S. patent application Ser. No. 2002/0117500A1,published Aug. 29, 2002 (now abandoned), entitled “Structures ForProviding A Removable Closure”, filed herewith, the entire disclosuresof which are incorporated herein by reference.

When hermetically sealed, the pressure of the interior chamber 36 willfluctuate depending on external conditions such as the surroundingatmospheric pressure and temperature. Accordingly, changes in altitude,weather and/or temperature, for example, may cause a significantfluctuation of the interior chamber pressure. In certain embodiments ofthe present invention, the container 30 is fabricated with asufficiently flexible material that permits the bottom wall 42 to bulgeor bow outwardly in response to increases in interior chamber pressure.In such embodiments, it is desirable to structure the container bottom38 to prevent formation of a rocker bottom (i.e., wherein the bottomwall permits rocking, tipping and/or rotation of the container 30) thatmight result if the bottom wall 42 bulges or bows outward to a pointbelow the lower-most portion of the container bottom 38.

In some embodiments, it is desirable to design the container 30 toresist formation of a rocker bottom at 7,500 feet above sea level. Inone example, the container bottom 38 can be designed with a sufficientinitial center height “H₃” (i.e., the initial difference in heightbetween the lower-most portion of the bottom wall 42 and the lower-mostportion of the container bottom 38, as shown in FIG. 11). For example,depending on the container wall thickness and material properties, therocker effect may be avoided by providing an initial center height “H₃”from about 0 cm to about 0.30 cm, and more specifically about 0.15 cm inexemplary embodiments. In exemplary embodiments, “H₃” may be zero orslightly greater than zero by fabricating the container bottom 38 from asufficiently rigid material and/or by providing the container bottom 38with a sufficient wall thickness or reinforcement to prevent undesirableoutward bulging or bowing of the bottom wall 42 when subjected to suchincreases in interior chamber pressure.

While certain embodiments may provide a container bottom with an initialheight “H₃”, greater than zero the container bottom should be able toprovide a bottom wall, such as a bottom wall with an inwardly concavesurface 44, sufficient to perform the desired function. For instance,exemplary embodiments of the radius “R₁” the inwardly concave surface 44(e.g., see FIGS. 8-9) can be from about 2 inches to about 6 inches, forexample, from about 3 inches to about 6 inches, and more specificallyabout 3.4 inches. The radius “R₁” may vary depending on a variety offactors, for example, the curvature and size of the snack pieces 70 tobe packaged.

As illustrated in FIG. 7, the container bottom 38 may include anoptional identification location or mark 52, for example, near thecenter of an outwardly convex surface 48 of the bottom wall 42. Anidentification mark can be used to convey recycle codes, identificationcodes, patent information, or other product-related information. In oneembodiment, if provided, the identification area or mark 52 may also belocated at or near the center 54 of the bottom wall 42. Theidentification area 52 may comprise a small and generally flat area inthe outer convex surface 48, if desired, to facilitate seating of alabel and/or protection of an applied label.

As shown in FIGS. 2 and 5, the container bottom 38 can extend beyond theperimeter of the container body 34. For example, the container bottom 38can be provided with an enlarged cross section when compared to thecontainer body 34, to thereby resist tipping of the container whileassisting in maintaining the container 30 in a substantiallyself-supported vertical orientation. Therefore, enlarging the containerbottom will increase the tip angle of the container, namely the angle atwhich the container may be tilted just before tipping over. Increasingthe tip angle reduces the likelihood of container tip overs by enhancingthe ability of the container to regain its vertical posture whenhandling, transporting or otherwise disrupting the container.

When a plurality of containers abut one another or are clustered inclose proximity, further instances of tipping might occur. For example,a plurality of identical containers may abut one another when shipping,packing, or transporting the containers on an assembly line. Particularproblems may exist, for example, if one portion of a laterally extendingcontainer bottom with insufficient vertical height is not mirrored withanother extension at a higher elevation along the elongated container.Such non-matching protrusion distances may permit slight tipping betweenadjacent containers. The cumulative effect of slight tipping betweenadjacent containers of a plurality of containers may cause one or moreof the containers to tip over as they pass their tip angle. Manyexemplary containers 30 may be designed with an upper lip 32 which alsoextends out beyond the perimeter of the container body 34, perhaps tothe extent of the container bottom, in order to at least partiallycounter the cumulative tipping effect. In exemplary embodiments, thecontainer bottom 38 and the lip 32 may extend from the container body 34from 0 cm to about 0.60 cm. In exemplary embodiments, the containerbottom 38 and the container lip 32 extend outwardly approximately thesame distance. In other exemplary embodiments, the container bottom 38extends further than the container lip 32 wherein additional structuremay be applied to the container lip, as described below, to at leastpartially counter the cumulative tipping effect.

As illustrated in FIG. 1, the container 30 may also include an over-cap68. The over-cap 68 protects the membrane lid 66 and/or acts as aclosure once the membrane lid 66 is removed. An exemplary over-cap foruse with the inventive concepts of the present invention is disclosed inU.S. Provisional Application No. 60/248,089, filed Nov. 13, 2000, andalso U.S. Publication No. 2002/0107127A1, publication date Aug. 8, 2002(now abandoned), the entire disclosures of which are incorporated hereinby reference.

The membrane lid 66 and the over-cap 68 will extend outwardly from thelip 32. Accordingly, in exemplary embodiments, the membrane lid 66and/or the over-cap 68 can extend outwardly from the upper lip 32 tohave approximately the same width as the enlarged container bottom 38 tothereby reduce or prevent the cumulative tipping effect between thecontainers.

Providing an enlarged container bottom 38 and an extended container lip32 may also create a recessed area along the container body 34 betweenthe container bottom 38 and lip 32. This area can also be designed toseat a label or other surface for displaying indicia contained thereon.Seating such a label or surface in the recessed area between the lip 32and the enlarged container bottom 38 can reduce scuffing, tearing,ripping, puncturing, or damaging of the label.

In exemplary embodiments, the lip 32 can extend outwardly beyond theperimeter of the container body 34 a distance of from about 0.20 cm inthe corner and to about 0.15 cm on the container sides, whereas, theenlarged container bottom 38 extends outwardly beyond the perimeter ofthe container body 34 a distance of from about 0.15 cm in the corner andto about 0.30 cm on the container sides.

Providing an enlarged container bottom 38 also assists in increasing thesurface area of the inwardly concave surface 44. In fact, with anenlarged container bottom 38 in accordance with the present invention,the outer edge 46 of the bottom wall 42 may have dimensionssubstantially equal to the cross-sectional profile of the container body34 to facilitate loading of chips within the container 30. Thus, inparticular embodiments of the present invention, the width “W₂” (bestillustrated in FIG. 7) can be less than or approximately equal to thecorresponding width “W₄” (best illustrated in FIG. 1) of the containerbody 34 wherein “W₄” equals the corresponding distance between theexterior or interior surfaces of the corners, for example.

In addition or as an alternative to an extending lip to assist inmaintaining the vertical orientation of the container, the containerbottom 38 may have a sufficient vertical height “H₂” (See FIG. 9) tohelp maintain a plurality of containers 30 vertically oriented if theyare introduced to abut one another. Indeed, as the vertical height “H₂”increases, leverage of a disrupting force is decreased, thereby reducingthe tendency of the containers to tip relative to one another.Increasing the vertical height “H₂” can also reduce “shingling” betweencontainers. Shingling occurs when one container bottom of a containerramps or rides up on the container bottom of another adjacent container.A sufficient vertical height “H₂” will reduce or even substantiallyprevent shingling by the substantial offset that would be required forone container bottom to ride on another container bottom. In order toreduce tipping and shingling of the containers while providing afeasible structure for blow molding, the vertical height “H₂” may be atleast about 3 mm. In another embodiment, “H₂” may be from about 10 mm toabout 30 mm. In still another embodiment “H₂” is about 18 mm.

FIGS. 13-15 illustrate another exemplary embodiment of a containerbottom 138 in accordance with other embodiments of the presentinvention. The container bottom 138 is similar to the container bottom38 described above. For example, the container bottom 138 includes abottom wall 142 having a convex outer surface 148 and a concave innersurface 144. As best illustrated in FIG. 15, the container bottomdefines a plurality of lateral cavities 150 defined between an innerwall 156 and an outer wall 158 of the container bottom 138. Each lateralcavity 150 extends along a side of the substantially triangular-shapedbottom, between two adjacent comers thereof. The container bottom 138may further include recessed corner portions 141 which are free of thelateral cavities 150 to reduce material costs and/or facilitate a blowmolding process.

FIGS. 16-18 illustrate yet another exemplary embodiment of a containerbottom 238 in accordance with other embodiments of the presentinvention. The container bottom 238 is similar to the container bottoms38 and 138 described above. The container bottom 238 comprises a bottomwall 242 having a convex outer surface 248 and a concave inner surface244. The container bottom further includes an inner wall 256 and anouter wall 258 defining a plurality of lateral cavities 250. As evidentfrom a comparison of FIGS. 16-18 with FIGS. 13-15, each of the lateralcavities 250 extends along only a portion of the side of thesubstantially triangular-shaped bottom between two adjacent comers. Thecontainer bottom 238 may further include recessed portions 241 at thecomers and adjacent side portions which are free of the lateral cavities250 to facilitate a blow molding process.

FIGS. 20 and 21 illustrate an exemplary embodiment of a container bottom338 similar to the container bottom 38 described above including abottom wall 342 having a convex outer surface 348 and concave innersurface 344. The concave inner surface 344 includes a circularlycylindrically concave surface having a radius of curvature “R₂” and acenter line of curvature 362. In one embodiment, the center line ofcurvature 362 intersects or is parallel with a bi-symmetrical plane 365of the container bottom 338. In still further embodiments, thebi-symmetrical plane 365 of the container bottom 338 contains the centerline of curvature 362, as shown in FIGS. 20 and 21. In additionalembodiments, the center line of curvature 362 is perpendicular to thegeometric central axis 364. In certain applications, it can bebeneficial to provide the center line of curvature 362 adjacent or alongthe bi-symmetrical plane 365 and/or oriented perpendicular to thegeometric central axis in order to facilitate alignment of the snackpieces relative to the container. In addition, as discussed above andwith reference to FIG. 19 for example, concave surfaces other thancircularly cylindrically concave surfaces may be used in accordance withthe present invention.

FIGS. 22 and 23 illustrate another exemplary embodiment of a containerbottom 438 similar to the container bottom 38 and 338 described aboveincluding a bottom wall 442 having a convex outer surface 448 andconcave inner surface 444. The concave inner surface 444 includes acircularly cylindrically concave surface having a radius of curvature“R₃” and a center line of curvature 462. In one embodiment, the centerline of curvature 462 intersects the bi-symmetrical plane 465 of thecontainer bottom 438. In still further embodiments, the center line ofcurvature 462 intersects and is perpendicular with respect to thebi-symmetrical plane 465 of the container bottom 438. In additionalembodiments, the center line of curvature 462 is perpendicular to thegeometric central axis 464. It can be beneficial to provide the centerline of curvature 462 perpendicular to the geometric central axis 464and/or the bi-symmetrical plane 465 in order to facilitate alignment ofthe snack pieces relative to the container. Moreover, as discussed aboveand with reference to FIG. 19 for example, concave surfaces other thancircularly cylindrically concave surfaces may be used in accordance withthe present invention.

The center line of curvature 362 illustrated in FIGS. 20-21 is orientedsubstantially 90° relative to the centerline of curvature 364illustrated in FIGS. 22-23 to accommodate a corresponding one of thesnack pieces illustrated in FIGS. 24-25 and FIGS. 26-27. In alternativeembodiments, the centerline of curvature could be located at otherrelative angles to accommodate various snack piece shapes.

FIGS. 24-25 illustrate another exemplary embodiment of a piece, such asa snack piece 370, that can be packaged in the containers and is adaptedto cooperate with container bottoms of the present invention. Inparticular, the snack piece 370 includes a circularly cylindricallyshaped inner concave surface 372 and a circularly cylindrically shapedouter convex surface 374. That is, the substantially triangular-shapedsnack piece 370 can be formed with a concavity that conforms to thesurface of a circular cylinder such that one edge 382 is curved whilethe other two edges 378, 380 remain substantially straight. The outerconvex surface 374 is defined as a radial distance “R₂” from the centerline of curvature 376. In one embodiment, the center line of curvature376 is parallel with or intersects a bi-symmetrical plane 385 of thesnack piece 370. In still further embodiments, the bi-symmetrical plane385 of the snack piece 370 contains the centers line of curvature 376,as shown in FIGS. 24 and 25. The curvature of the snack piece 370 may bedesigned such that the outer convex surface 374 has a radius “R₂”similar or identical radius of curvature “R₂” of the inwardly concavesurface 344 of the bottom wall 342 of the container bottom 338 (SeeFIGS. 20-21).

FIGS. 26-27 illustrate yet another exemplary embodiment of a piece, suchas a snack piece 470, that can be packaged in the containers and isadapted to cooperate with container bottoms of the present invention.The snack piece 470 may have a circularly cylindrically shaped innerconcave surface 472 and a circularly cylindrically shaped outer convexsurface 474. That is, the substantially triangular-shaped snack piece470 can be formed with a concavity that conforms to the surface of acircular cylinder such that two edges 478, 480 are curved while thethird edge 482 remains substantially straight. The outer convex surface474 is defined at a radial distance “R₃” from the center line ofcurvature 476. In one embodiment, the center line of curvature 476intersects a bi-symmetrical plane 484 of the snack piece 470. In stillfurther embodiments, the center line of curvature 476 is perpendicularto the bi-symmetrical plane 484 of the snack piece 470. The curvature ofthe snack piece 470 may be designed such that the outer convex surface474 has a radius “R₃” similar or identical radius of curvature as theradius of curvature “R₃” of the inwardly concave surface 444 of thebottom wall 442 of the container bottom 438 (See FIGS. 22-23).

Inventive methods of loading a plurality of pieces (i.e., articles) in acontainer will now be described with reference to FIGS. 3-5. In oneembodiment, the method includes the steps of providing a container 30defining an interior chamber 36 and comprising a bottom wall 42including an inner surface 44. In certain embodiments, the inner surface44 is substantially planar while other embodiments provide a surfacethat is concave towards the interior chamber. A stack of articles isalso provided (e.g., see 70 generally in FIG. 3). In some embodiments,although not shown, each of the articles have a substantially flatsurface. In additional embodiments, each of the articles of the stack ofarticles includes a convex surface 74 for engagement with the concavesurface 44 of the bottom wall 42. In particular embodiment, the articles70 each comprise a thin piece with a convex surface 74 on one side and aconcave surface 72 on the other side.

As illustrated in FIGS. 3 and 4, the method of loading further includesthe step of inserting the stack of articles at least partially into theinterior chamber until the leading article 71 of the stack of articlesinitially contacts the concave surface 44 of the bottom wall 42 at aninitial contact point 43. In fact, a leading surface portion of theconvex surface 74, rather than an edge of the article, contacts theconcave surface 44 of the bottom wall 42 at the contact point 43. Thecurvature of the snack piece surface, especially the leading surfaceportion of a convex surface of the snack piece, and the surface of thebottom wall should be structured to facilitate reorienting the leadingsnack piece, and remaining snack pieces, in proper stacked alignment.Snack pieces having planar surfaces may be reoriented when the bottomwall has a concave surface with a sufficiently small radius of curvaturewhile a planar bottom wall may be effective to reorient a snack piecehaving a convex surface with a sufficiently small radius of curvature.

Providing a defined relationship between the surface configuration ofthe snack piece and the bottom wall surface configuration permits thedesired reorientation. More specifically, a sufficiently low AngleBetween Tangent(s) (“ABT”) will permit proper reorientation of theleading snack piece. The ABT can be viewed along a sectional planeincluding the initial point of contact (initial point of contact 43 asseen in FIG. 4) and extending parallel with or including the geometriccentral axis (geometric central axis 64 as seen in FIG. 4) of thecontainer bottom. The initial contact point is the point on the innersurface of the bottom wall where the leading snack piece 71 initiallycontacts the bottom wall 42 when loading a stack of snack pieces withinthe interior chamber of the container. In exemplary embodiments, the ABTis the angle between a tangent line of a curved surface of a snack pieceat the initial contact point and the tangent line of the concave bottomsurface at the initial contact point. In alternative embodiments, theABT is the angle between the substantially planar surface of asubstantially planar snack piece and the tangent line of the concavebottom surface at the initial contact point. In still furtherembodiments the ABT is the angle between a tangent line of a curvedsurface of a snack piece at the initial contact point and thesubstantially planar surface of a substantially planar bottom wall. Witha snack piece having surface informalities, such as bubbles protrusionsor the like, the tangent (or the substantially planar surface) of thesnack piece is approximated from the overall curved or flatconfiguration of the snack piece.

In one example, as shown in the schematic cross section of FIG. 4, alonga cross sectional plane including a geometric central axis 64 and theinitial contact point 43, the ABT is the angle between the tangent line73 of the convex surface 74 of the leading snack piece 71 at the contactpoint 43 and the tangent line 45 of the concave surface 44 at thecontact point 43.

In the exemplary embodiments described above, the ABT not greater thanabout 45°. In more particular embodiments, the ABT is not greater thanabout 35°. In still more particular embodiments, the ABT is not greaterthan about 25°. In further particular embodiments the ABT is not greaterthan about 15°.

Turning to FIGS. 5 and 6, for example, the snack piece 70 can have alength “L₁” of about 65 mm with a spherically convex surface 74 having aradius of curvature of about 54 mm (i.e., the radius of curvature R₄ ofthe concave surface 72 plus the thickness of the snack piece 70). Topackage this snack piece with an ABT of about 35°, the sphericallyconcave surface 44 of the bottom wall 42 can be designed with a radiusof curvature R₁ of about 86 mm.

With respect to FIGS. 26 and 27, another exemplary snack piece 470 canhave a length “L₂” of about 55 mm with a convex surface having a radiusR₃ of about 33 mm. A snack piece having this radius of curvature couldbe loaded against a substantially flat bottom wall while maintaining theABT between 24° and 28°. For example, when loading a snack piece withthis curvature against a substantially rigid bottom wall, the ABT isabout 28°. In other embodiments, the bottom wall may have limitedflexibility. For example, a bottom wall can comprise a membrane thatwill later act as a removable membrane lid of the container. When theleading snack piece engages the membrane, the membrane may flex suchthat the membrane displays a curvature that substantially conforms to asphere with a radius of about 200 mm at the point of contact. With thisflexing of the membrane at the contact point, the resulting ABT can bereduced to about 24°.

The leading surface of a snack piece could also be designed with asufficient radius, that might be different or the same as the radius ofthe other chip surfaces to provide a sufficient ABT for loading.

The maximum ABT angle permissible may change due to frictional forcesbetween the chip and bottom wall. For example, the maximum ABT may needto be reduced when the coefficient of friction of the materialsincreases.

Loading of chips can be achieved with a variety of structures and/orprocesses. For example, although not shown, a plunger, trough, orloading mechanism may be used to load articles. As illustrated in FIGS.3-5, the method of loading a plurality of pieces further comprises thestep of reorienting the leading article 71 by forcing the leadingarticle against the surface of the bottom wall (e.g. the concave surface44 of the bottom wall 42). A wide variety of methods could be used toforce the leading article 71 against the bottom wall surface. Forexample, an actuator such as a plunger could be used to force thearticles into the container. In still another embodiment, a plurality ofarticles could be stacked on a trough wherein the trough and/or thecontainer 30 are pivoted such that the force of gravity forces the stackincluding the leading article 71 such that the leading article 71 isforced against the surface of the bottom wall. In one particularexample, a trough could be lined up with the opening of the containerwith a plurality of articles located on the trough. The trough andcontainer can be rotated together such that the articles slide into thecontainer until they form the stack similar to the stack of articles ina container shown in FIG. 5. It will be understood that the loadingangle of the rotated container and trough should be sufficiently largeto cause a sufficient article velocity but should be small enough toavoid excessive velocities that might otherwise crush or break one ormore of the articles due to the impulse generated by colliding with thebottom wall.

In still another embodiment, the stack of articles could be inserted inthe interior chamber and then the container 30 could be rotated withrespect to the vertical direction to allow the force of gravity to movethe stack of chips toward the bottom and force the leading chip 71against the concave surface 44. Thus, the leading article 71 may beforced against the concave surface by directly moving the stack orsimply rotating the container to permit the force of gravity to move thestack.

In still further embodiments, the stack of articles could be insertedinto the interior chamber 36 of the container such that the stack ofarticles is inserted in a substantially horizontal direction during atleast a period of time when loading. This may likely occur if thecontainer 30 is oriented in the horizontal position when receiving thearticles. In another example, the stack of articles could be inserted ina substantially non-horizontal direction during a period of time. Forinstance, the container could be tipped to a loading angle wheninserting the articles in a substantially non-horizontal direction. Theloading angle would permit the chips to be loaded by sliding down intothe container under the influence of gravity. The load angle could beenlarged to increase the velocity of the chips as they are entering thecontainer, thereby reducing the article loading time for each container.Moreover, the loading angle of the container could be decreased toreduce the velocity of the articles to an appropriate level to reducearticle breakage that might otherwise occur as the leading chip impactsthe bottom wall. Further, the loading angle of the container could bemodified throughout or at least once while inserting the stack ofarticles in the container. For example, the container could be tipped ata large initial load angle to provide the chips with a larger initialvelocity and then reduced to a final load angle before the leading chipexperiences the impulse from contacting the bottom wall. Therefore, theloading time can be reduced while minimizing the impulse of the articlescontacting the bottom wall.

The specific embodiments and examples set forth above are provided forillustrative purposes only and are not intended to limit the scope ofthe following claims. Additional embodiments of the invention andadvantages provided thereby will be apparent to one of ordinary skill inthe art and are within the scope of the claims.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method of loading a plurality of articles in a container comprisingthe steps of: a) providing a container defining an interior chamber, thecontainer comprising a bottom wall including an inner surface; b)providing a stack of articles; c) inserting the stack of articles atleast partially into the interior chamber until a surface portion of theleading article of the stack of articles contacts the inner surface ofthe bottom wall with an Angle Between Tangents of less than or equal toabout 45°; and d) reorienting the leading article by forcing the leadingarticle against the inner surface.
 2. The method of claim 1, furthercomprising the step of rotating the container to change the orientationof the container with respect to a vertical axis.
 3. The method of claim1, wherein the stack of articles are inserted in a substantiallyhorizontal direction.
 4. The method of claim 1, wherein the innersurface is flat.
 5. The method of claim 1, wherein the inner surface isconcave towards the interior chamber.